Reliability improvement masterclass
In-company / open course Yes / Yes Duration 1 Day
Reliability improvement masterclass
Course leaders
Martin Brown is a consultant and experienced practitioner involved in improving maintenance, reliability and integrity management for a wide range of companies across the chemical, oil & gas, power and pharmaceutical industries.
Laurence Plant is a consultant with a maintenance and engineering background in pharmaceuticals, chemicals FMCG and plastics. Laurence has been involved in a wide range of reliability improvement projects.
Agenda
Registration and coffee Introduction
Reliability - The basics Criticality analysis Coffee and networking Loss analysis and reporting Root Cause Analysis Lunch and networking
Failure Modes and Effects Analysis Coffee and networking
Spares management
Key Performance Indicators (KPIs) and benchmarking Maintenance and reliability issues - CEDAC
Today UK industry must be as efficient as possible to compete in the global market place. A key driver for this is the reliability of the plant assets.
What the course will cover
The use of a structured Root Cause Analysis method to find the fundamental cause of a problem.
The practical application of the technique to real-life examples.
Who will benefit and what will they gain? Anybody who would value a structured approach to identifying the root cause of a problem.
Organisations who want to give their staff tools to help solve work related problems.
On completion delegates will be able to − Clearly define a problem
− Apply the “5 Whys” root cause analysis process
− Create a cause tree diagram to document the RCA process
− Eliminate potential but incorrect causes − Identify the primary or Root Cause of a
problem
Course leaders
Martin Brown is a consultant and experienced practitioner involved in improving maintenance, reliability and integrity management for a wide range of companies across the chemical, oil & gas, power and pharmaceutical industries. Laurence Plant is a consultant with a maintenance and engineering background in pharmaceuticals, chemicals FMCG and plastics. Laurence has been involved in a wide range of reliability improvement projects.
Root Cause Analysis
In-company / open course Yes / Yes Duration 1 Day
Root Cause Analysis
Agenda
Registration and coffee Introduction
Why do we want to get to the root cause?
Problem definition
How to define a problem clearly and accurately
RCA process
The ‘5 whys method Lunch
Recording an RCA The cause tree diagram Finding the primary cause How to eliminate incorrect causes RCA group exercise
The ‘Nail bed’ problem Close
Are you equipped to manage an event that may have a significant impact on your business’s financial performance and the reliability and integrity of its assets?
There is no doubt that engineers are faced with ever increasing challenges when managing shutdowns, turnarounds and outages. They are highly complex events with significant pressure to succeed against tight timescales, constrained budgets and resources and a need to achieve the highest possible HSE standards. Without an understanding of a structured approach to shutdown management achieving the goals of a successful event would be virtually impossible. ABB Consulting has designed a course specifically to enhance the skills that you will need to manage a successful shutdown. It is based upon ABB’s shutdown, turnaround and outage model of excellence and our consultants’ extensive practical experience of shutdown management.
What the course will cover
The course will provide a practical approach to managing a successful shutdown, turnaround or outage. Over the two days the main areas of shutdown, turnaround or outage planning and execution will be reviewed together with a number of interactive group exercises. A course dinner will be held on the first night to enable you to network effectively with other course participants.
Who will benefit and what will they gain? Anybody from the oil & gas, chemicals, petrochemicals, power, pharmaceuticals and other process industries who are involved in or impacted by the execution of shutdowns, turnarounds and outages on their facilities. It will be of particular interest to:
− Current or potential future shutdown, turnaround or outage managers − Project engineers and managers
− Plant maintenance engineers and reliability engineers
− Plant / operations managers
− Shutdown, turnaround or outage planners and coordinators
Course leaders
Martin Brown is a consultant and experienced practitioner involved in improving maintenance, reliability and integrity management for a wide range of companies across the chemical, oil & gas, power and pharmaceutical industries. Laurence Plant is a consultant with a maintenance and engineering background in pharmaceuticals, chemicals FMCG and plastics. Laurence has been involved in a wide range of reliability improvement projects.
Shutdown, turnaround and outage
management
In-company / open course Yes / Yes Duration 2 Days
Shutdown, turnaround and outage management
Day 1
Registration and coffee Introduction and overview
Identifying critical elements of the shutdown, turnaround or outage
How these elements interact Group exercise
What issues have you encountered with shutdown, turnaround or outages in your organisation?
The model of excellence
The framework for turnaround excellence How this can be used
Outline and detailed models of excellence Turnaround safety
Hazards
Safe systems of work Safety plan
Permit to work Audits
Group exercise
Shutdown, turnaround or outage safety plan Shutdown, turnaround or outage quality The need for quality
Quality assurance issues Quality control and issues
Shutdown, turnaround or outage organisation Factors affecting organisation
Different kinds of organisation Competency and skills Team building Group exercise Organisation design Drinks reception Dinner Day 2 Planning Phases of planning Work listing Work scope Group exercise
Generating a cost-effective workscope Planning levels and norms
Planning sequences Group exercise Planning a hazardous task Contractors
Limits of outsourcing
Upside and downside of contracting Commercial awareness and contractor engagement
Cost control and estimation
Business plan and impact of turnaround Cost control and reporting
Cost estimation models Where money is spent Group exercise Costs and assumptions Logistics
Defining and handling site logistics Organising stores
Marshalling bulk work Group exercise Strategic issues Execution
Stages of the shutdown, turnaround or outage Meetings and routines
Controlling the event Performance review
“How much does poor project delivery cost your business; and what would it be worth to make a step change in performance?” “Doing the wrong projects well is not much help”
Good project management needs to address both:
− How to identify and define the best project to meet the business objectives, and − How to deliver that project in a safe, cost
effective way
ABB Consulting has good experience of providing project management training to operating companies in the process industry. We understand the particular challenges that are faced by companies in the chemical, oil & gas and power sectors when delivering complex and potentially hazardous projects in a highly regulated environment. Our trainers all have strong backgrounds in projects, engineering and operations in the process industry and are able to bring their own experiences to the training courses that we run. What the course will cover
− A generic project process and the key elements of a successful project − The role and skills of the project manager − Managing key interactions, stakeholders and
the project team
− Key tools for use through the project lifecycle - planning, scheduling, risk management and option analysis
Who will benefit and what will they gain? The training is aimed at people newly appointed into project positions including: − Project managers
− Project engineers − Project participants
On completion you should be able to: − Define project objectives that align with
business objectives
− Know the features of and see the benefits of a well managed project
− Understand how to identify and manage key stakeholders
− Understand and have practised the core tools and techniques required as a project participant or manager
− Understand the key skills required as a project participant or manager Course leaders
John Weston is an experienced project manager and project control consultant, with particular expertise in managing
multifunctional project teams and consultancy assignments in various industry sectors.